Method of weaving pile fabrics



NOV. 12, 1935. A J DACEY 2,020,460

METHOD OF WEAVING PILE FABRICS Filed April 15) 1933 a FIEE 1 j sruxentor' B a adumrd J. Dace altofiheq 2 with consequent unevenness of, pile. shearing operation it is therefore necessary to re- Patented Nov. 12, 1935 PATENTVOFFICE a 2,020.400' METHOD or wEAviNe rim memos Edward J. Dacey, Philadelphia, Pa., assignor to Crompton & Knowles Loom Works, Worcester, Mass., a corporation of Massachusetts Application April 13, 1933, Serial No. 665,918

v5 Claims.

This invention relates to the production, of pile fabrics more particularly those having the pattern showing on theback and it is the general object of the invention to provide an'improved method of producing the fabric to eliminate waste in the shearing orfinishing operation.

Axminster fabrics are produced on a loom operating with a series of tube frames each of.

which has a plurality of yarn tubes from which project tuft yarns. The tubes are projected between the binder and stuiier warps and the tuft yarns are then curled rearwardlv and upwardly.

behind a pickof filling. The tuft yarns and pick of filling are then :moved forwardly to be incorporated into the fabric, afterwhichthe tube frame is raised to pull off yarn for the next row of tufts to be formed thereby, and the tufts are then cut from the yarns offthe tube frame. In three-shot Axminster fabrics a pick of filling is laid behind the tuft after the cutting operation. In three-plane Axminster fabrics having the pattern on the back it has been customary prac- 'tice to beat the third pick into the fabric in such a way as to cause. .a partial wrapping of one'side of the tuftaround the previously laid pick, 're-,

sulting in ashortening of this part. of the tuft move considerable. pile in order to produce a smooth surface.

In my present invention I have altered the sequence in which-the shots of filling are laid so that anycrimping or shortening of the tuft incident to the'beating-in of the. filling will take place before the tufts are cut from the tube frame. As set forth herein there will be a certain amount of bending of the tuft yarn around one fabric having the tuft yarn around the bottom shot. wherein the first shot to be laid is not beaten all the way to the fell, but is kept in a rearward position while the tuft yarns are in-' .serted between the binders. A second pick is then inserted behind the tuft yarns, whereupon both of these picks are beaten to the fell to occupy the bottom and middle planes of the finished fabric. After cutting the tufts from the tube frame, the third pick is beaten into the top plane of the fabric above the other two picks.

With these and other objects in-view which willappear as the description proceeds, my ininthe vention resides in the combination and arrangement of parts hereinafter described and set forth in the claims.

In the accompanying drawing, wherein a convenient embodiment of my invention is set forth, 5 Fig. l is a longitudinal vertical section through a fabric made according to my present invention, the different systems of threads being spaced farther apart .thah is true in the woven fabric for the sake of clearness,

Fig. 2 is a diagrammatic view showing the order in which the picks are laid, the picks of any one cycle being inclosed inan outline, and

Figs. 3 to 7 represent diagrammatically successive positions of the systems of threads and as- 15 sociated parts in the practice of my invention.

The method of weaving set forth hereinafter is intended for practice in a loom such as that shown in co-pending applications Serial Nos. 575,190 and 574,174. I do not wish the practice of my'invention to be limited, however, to the loom shown in the first of the aforesaid applications, or by the process shown in the second of said applications.

As shown in Fig. 1, the fabric forming the sub- 2 'ject matter of the present invention has its weft threads divided into three horizontal planes by means of upper and lower stufiers S, and 8, respectively. A binder warp B may extend around the fllling threads as suggested in Fig. 1. The position of the reed R indicates the sequence in which the picks are inserted, the reed of course being at the rear of the fabric so that the pick which is nearestit is the last to be laid.

As shown in Figs. 3 to '2, the invention is used in conjunction with a nose board 20 which has a number of separate teeth 2| each with an upwardly extending hook 22 having a rear face 23. The yarn tubes 24 of the tube frame not shown carry the color or tuft yarns Y for forming the tufts. The shots of filling are'indicated by circles in which are numerals to indicate the order in which the shots are laid.

As shown in Fig. 3, the first shot of filling l to be laid in the cycle lies between the stulfers and left behind the hooks 22, being beaten to this position by the reed which for the purpose is given a short forward stroke. The tube frame is then given a normal dipping motion, such as set forth in the aforesaid applications, to'project the tuft yarns down through the binders and warps, as suggested in Fig. 3. A set of spaced plates 25- may be employed to separate the tuft yarns and keep them in parallel relation.

After the tuft yarns are disposed as shown in u Fig. 3, a second shot of filling 2 is laid below the stuffers and behind the tuft yarns, as shown in Fig. 4. The plates 25 guide the tuft yarns as they are moved forwardly by the reed R with the first and second shots over the hooks 22. During this operation the tuft yarns are bent upwardly so that their rear ends assume the position 26 in Fi 5.

The yarn tubes are then raised from the full to the dotted line position shown in Fig. 5 to pull of! yarn for another row of tufts. The front and rear knives 21 and 28, respectively, then come into play to cut the tufts from the tube frame, and the tube frame is returned to the chain not shown, leaving a tuft with equal halves as shown in Fig. 6.

The third shot of filling 3 is then laid over the stuffers as indicated in Fig. 6 and beaten ,to the fell of the cloth, see Fig. 7. 4

So far as the manipulation of the tube frame,

nose board, spacingplates, pulling-oil? of tube frame, and cutting are concerned, my present method may be carried out substantially the same before the cutting, these two picks deforming the tuft yarns somewhat as shown in Fig. 5 so that any shortening of either front or back portion of the tuft due to binding by the picks takes place prior to cutting. The third pick of filling is laid after cutting and is placed in the top plane where it has no appreciable effect in varying the heights of the parts of the tuft. The order in'which the shots are laid is indicated in Fig. 2, where the shots of each cycle corresponding to a tuft are enclosed in a line C.

As seenin Fig. 5 there is a single strand of the tuft yarn between the first and second shots, while there are two strands of the tuft between the first and third shots.

When the first shot rides over the second to curve the tuft yarns backwardly a slight amount,

as in Fig. 5, there results a tensioning of the tuft yarns which serves to give a neatly defined pattern on the back of the fabric.

It is to be understood that the process set forth herein can be carried out advantageously with an Axminster loom operating with tube frames wherein each of thelatter carry a supply of tuft forming yarn which projects through tuft tubes which are manipulated in the usual manner. The pulling-oil operation of the tube frame takes place prior to the cutting and therefore at a time in the cycle of operation when it is effective to tighten the tuft yarns'around the first and second picks of filling. Also in this type of 106m the crimping or deforming of the tufts around certain of the shots, together with the pulling-off, subjects the tuft yarns to their maximum strain either before or just at the time of cutting.

From the foregoing it will be seen that I have provided a method of weaving a three plane fabric having the pattern on the back wherein the shots of filling are laid so that any shortening of the sides of the tufts due to binding b'etween picks will occur before the tufts are cut from the tube frame. Furthermore, the top shot is so placed that it will not affect the height of the tuft halves, and this tuft is laid after cutting. Also, the process is carried out on an Axminster type of loom operating with tube frames which are raised to pull off yarn for a later tuft, this raising preceding cutting and therefore eifective to tighten the tuft yarns extending around the bottom shot in the fabric. 5

a shot of filling between the stuflfers, placing tuft 15' forming yarns behind said shot and between the stufiers, inserting another shot of filling below the stuffers and behind the tuft yarns, bending the tuft yarns around the second named shot to form tuftsbeating both of said shots of filling and 20 tufts to the fell of the fabric on the same heat of the loom, cutting the tufts from the tuft yarns. laying a third shot of filling above the stuffers and behind the tufts, and beating said third pick to the fell of the fabric on a later beat of the loom. 25

2. The method of weaving. a tuft fabric having a pattern on the back by means of a ncse board having a rearwardly and upwardly inclined surface terminating in hooks, said method consistingin supplying a pair of spaced stuffer warps. 30 inserting a shot of. filling between said stufi'ers, beating said shot to aposition behind the hooks, inserting the tuft ends of a supply of tuft yarn behind said shot, laying a second shot'behind the tuft yarns and below-the stufl'ers, beating both of 35 said shots and the tuft yarns up said inclined surface to a position in front of the hooks, raising the supply to tighten the tuft yarns around said shots, cutting said tuft yarns from the supply, and thereafter supplying a third shot of filling above 40 the stuffers and behind the tuft yarn.

3. The method of forming a pile fabric having I the pattern on the back by the use of a nose board having upwardly and forwardly inclined surfaces leading to hooks and a tube frame hav- 6 ing a supply of tuft yarn extending from tuft tubes, said method consisting in providing a pair of spaced stufier warps, laying a shot of filling between thewarps and beating the same to a position behind the hooks, dipping the tube frame 50 to place the tuft yarns between the stuffers and behind said shot of filling, inserting a second shot of filling beneath said stuifers and behind the tuft forming yarns, beating both of said shots of filling and the tuft yarns up said inclined sur- 86 faces and over said hooks to a position in front of the latter, raising the tube frame to pull all yarn for another row of tufts and thereby tension the tuft yarns, cutting the tufts from the supply, thereafter inserting a thirdshotof filling above 00 the stuffers and beating the same' over the hooks against the rear 'of the tufts, and providing a binder warp to hold the shots above and below the stuilers. j

4. The method of forming a pile fabric I the pattern on the back by the use of anose board having upwardly and forwardly inclined surfaces leading to hooks and a tube frame having a supply of tuft yarn extending from tuft tubes, said method consisting of providing two stuffer warps 10 and a binder warp to extend above and belowthe stufiers, inserting a shot of filling between stuffers, beating the same to a position behind-the hooks, dipping the tube frame to place the tuft forming yarns between the stuffer and'binder 7 inserting a shot of between the stufl'er warps and behind said shot of filling, inserting a second shot of filling beneath the stuffers and above the binder warps, beating both shots of filling and the tuft forming yarns over the hooks rear of the tufts.

5. The method of. forming a pile fabric having the pattern on the back by the use of a nose board having upwardly and forwardly inclined surfaces leading to hooks and a tube frame having a supply of tuft yarn extending from tuft tubes, said method consisting in providing a pair of spaced stuifer warp threads and a binder warp thread,

warps, beating the same to a position behind the hooks, dipping the tube frame to position the tuft forming yarns between the stuffer and binder warp threads and behindsaid shot, inserting a second shot of filling below the stuflers and above the 4 binder warp, beating said shots of filling and the tuft forming yarns together overthe hooks to a position in front of the latter, raising the tube frame to pull of! yarn for another row of tufts and thereby tension the tuft forming yarn, there- I after cutting the tufts from the supply, and inserting another shot of filling over the stutter warp threads and under the binder warp threads and beating said third shot of fillingagainst the tufts.

" EDWARD J. DACEY. 

